Molded Body, Sandwich Panel Using Same And Method For Manufacturing Same

Abstract

The present invention relates to a molded body, a sandwich panel using same as a core layer, and a method for manufacturing same, the molded body having a non-woven fiber aggregate structure comprising two or more non-woven fiber aggregates. The molded body comprises a polyester-based fiber and a polypropylene composite fiber, wherein the polypropylene composite fiber comprises polypropylene and maleic anhydride polyolefin.

1 . A molded body having a non-woven fiber aggregate structure comprising two or more non-woven fiber aggregates, comprising:
 a polyester-based fiber and a polypropylene composite fiber,   wherein the polypropylene composite fiber comprises polypropylene; and maleic anhydride polyolefin.   
     
     
         2 . The molded body of  claim 1 , wherein the maleic anhydride polyolefin is grafted with polyolefin and maleic anhydride. 
     
     
         3 . The molded body of  claim 2 , wherein the polyolefin comprises a monomer selected from the group consisting of ethylene, propylene, and combinations thereof, and the polyolefin has a homopolymer structure. 
     
     
         4 . The molded body of  claim 2 , wherein the polyolefin is polypropylene having a homopolymer structure. 
     
     
         5 . The molded body of  claim 1 , wherein the non-woven fiber aggregate structure comprises,
 with respect to the total weight of the polyester-based fiber and the polypropylene composite fiber,   35 to 75 wt % of the polyester-based fiber and   25 to 65 wt % of the polypropylene composite fiber.   
     
     
         6 . The molded body of  claim 1 , wherein the non-woven fiber aggregate structure comprises,
 with respect to the total weight of the polyester-based fiber and the polypropylene composite fiber,   35 to 65 wt % of the polyester-based fiber and   35 to 65 wt % of the polypropylene composite fiber.   
     
     
         7 . The molded body of  claim 1 , wherein the polyester-based fiber is at least one selected from the group consisting of polyethylene terephthalate (PET), polytrimethylene terephthalate, polybutylene terephthalate and polyethylene naphthalate. 
     
     
         8 . The molded body of  claim 1 , wherein the non-woven fiber aggregate structure is a structure in which two or more non-woven fiber aggregates are bonded, and
 the non-woven fiber aggregates are formed by bonding non-woven fibers on a web or sheet with an adhesive or using a thermoplastic fiber.   
     
     
         9 . The molded body of  claim 1 , wherein the flexural rigidity of the molded body is 0.55 to 1.05 GPa. 
     
     
         10 . The molded body of  claim 1 , wherein the flexural strength of the molded body is 60 to 135 N. 
     
     
         11 . A sandwich panel comprising:
 a core layer;   a skin layer laminated on at least one surface of the core layer; and   a bonding layer bonding the core layer and the skin layer,   wherein the core layer uses the molded body of  claim 1 .   
     
     
         12 . The sandwich panel of  claim 11 , wherein the flexural rigidity of the sandwich panel is 30 to 50 GPa. 
     
     
         13 . The sandwich panel of  claim 11 , wherein the flexural strength of the sandwich panel is 1500 to 3000 N. 
     
     
         14 . The sandwich panel of  claim 11 , wherein the skin layer is at least one selected from the group consisting of aluminum, iron, stainless steel (SUS), magnesium, electro-galvanized iron (EGI) and galvanized iron (GI). 
     
     
         15 . The sandwich panel of  claim 11 , wherein the bonding layer includes at least one of an olefin-based adhesive, a urethane-based adhesive, an acrylic adhesive, and an epoxy-based adhesive. 
     
     
         16 . A method for manufacturing a sandwich panel comprising steps of:
 a) preparing non-woven fiber aggregates by mixing a polyester-based fiber and a polypropylene composite fiber;   b) preparing a core layer by performing a needle-punching process for the non-woven fiber aggregates at the number of times of punching per minute of 300 to 1000 times, a movement speed of 1 to 8 m/min, and a punching density of 100 to 500 punches/cm 2 ;   c) forming a bonding layer on at least one surface of the core layer; and   d) forming a skin layer on the bonding layer.